North American chemical producer Flint Hills Resources (FHR) is promoting the development and use of an advanced design, high-alloy valve trim that helped them dramatically increase production uptime while reducing maintenance costs. Collaborative efforts generated a unique, high-alloy Fisher SS-83 control valve trim to address service issues with FHR’s vessel-mounted valve that was causing significant downtime and extensive maintenance at their Joliet Chemical Plant south of Chicago.
In meetings with Emerson local business partner Novaspect, FHR expressed concerns with the existing Fisher valve used in the production of purified isophthalic acid (PIA), as it required frequent (planned and unplanned) maintenance due to regular sticking issues and packing leaks. At that point, FHR made the decision to partner with Emerson to develop and install a new valve trim that would alleviate those concerns and protect the company’s catalysts and associated operations from extensive damage.
Through data analysis and investigation into similar installations, Emerson engineers found that FHR needed a custom trim design to ensure proper operation. Working from current process data rather than a dated spec sheet, Emerson engineers were able to size and select high-alloy components with a new SS-83 trim set that fit the operating conditions into a wider control range using a smaller port size. The new design also included low-emission packing and a lubrication option to reduce sticking.
Since installation of the new trim, FHR has seen significant savings associated with the reduced maintenance and production downtime. Between 2010-15, the valve required maintenance 2-4 times annually; but after installing the new trim in late 2015, no work orders have been required. Because of the unique relationship between Emerson and FHR, Emerson Lifecycle Services has developed a cost-effective plan to refurbish the high-alloy trim, which utilizes assistance from specialized welders at FHR to bring the valve trim back to OEM tolerances at the service center. This collaboration will save FHR tens of thousands of dollars during each repair cycle by eliminating the purchase of a new high-alloy trim set.